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My New Project arrives after a 44 year wait!

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Bryanj:
Used to be very common Ted as when people fitted the small crankcase crashbars they came with a longer bolt to accomodate the steel bracket, then later on a "new" owner would remove the damaged and bent crashbars and just screw the long bolt back in cracking the crankcase, cant remember how many i had to repair

Laverda Dave:

--- Quote from: Bryanj on December 16, 2023, 11:01:49 AM ---Used to be very common Ted as when people fitted the small crankcase crashbars they came with a longer bolt to accomodate the steel bracket, then later on a "new" owner would remove the damaged and bent crashbars and just screw the long bolt back in cracking the crankcase, cant remember how many i had to repair

--- End quote ---

Guilty as charged Bryan  :o. I did the same thing with my first 400/4 in 1981. When I bought the bike it had crashbars fitted that were rusty so I took them off and put the bolts back in. I went out for a ride and when I came back to the bike the tell-tale oil mark was bellow the r/h side of the engine, I'd cracked the casing  :(. I bought a s/h engine for £50.

When I was checking the inside of the lower crankcase after the outside weld repair I noticed what I thought was another crack in the oil gallery. I used a bit of fine grade wet & dry and rubbed at the 'crack' hoping the damage on the outside hadn't come right through, luckily the 'crack' rubbed out and it was just a casting mark. Once you start looking though the cases are full of these marks especially inside.

andy120t:
Long bolts?
On my first 500/4 (which was a bit of a mongrel with a non-standard/Comstar front end), I had long disc bolts  and put them in the wrong way round so they fouled and cracked the speedo  drive.

Being young, silly, unaware...etc..I didn't think why it was cracked, just replaced it and soon found it cracked again. I think in the end I replaced ithe drive four times before I worked out why!

AshimotoK0:
My worst one was on a CB72 when I was 18. I fitted a mudguard bolt that was too long into the fork bottom and when I tightened it,  it distorted the tube and locked the stanchion to the fork lower. My mate Graham Curtis has seen a lot of forks damaged like that
 The fork bottom has an inner tube welded inside and no way to get at the distortion to try to fix it. That is after you have got the forks apart, which is very difficult and also trashes the bush as the damaged fork lower gouges a deep groove into the bronze bush. Graham  told me he was going to devise some sort of special reaming tool to fix the damaged ones he encounters but not sure how far he got with it.

Laverda Dave:
The silly two minute mistakes are always the ones that cost a lot of time and a small fortune to fix not to mention the embarrassment when you ask a pro to fix it and tell them how you bodged it in the first place!

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